Automatic cover assembly for a swmming pool

ABSTRACT

A drive arrangement for moving a pool cover between an extended position and a retracted position. The drive arrangement includes a tube, at least one reel, a first motor and a second motor. The tube has a first end, a second end and an internal opening with an inside diameter. The at least one reel is configured for winding of a pair of lines. The first motor is positioned at least partially within the internal opening of the tube. The first motor engages the inside diameter of the tube and is configured to retract the cover. A second motor positioned at least partially within the internal opening of the tube. The second motor engages the at least one reel, and is configured to retract the pair of lines.

BACKGROUND OF THE INVENTION 1. Field of the Invention

The present invention relates to swimming pools, hot tubs, spas, swim spas, and the like, and, more particularly, to automatic cover assemblies for such containers.

2. Description of the Related Art

Swimming pools and hot tubs, for example, are commonly covered with covers. Covers have many uses, including: slowing down or stopping evaporation; cutting down on chemical use; retention of heat in the swimming pool or the hot tub; keeping out leaves, twigs and other yard debris; reducing the amount of maintenance such as vacuuming less often; saving money by cutting down on energy costs associated with refilling with water, heating the water and cleaning the water; increasing safety by preventing someone from falling in; and conserving water. An automatic cover provides convenience for a user by allowing the cover to be easily extended over the pool or the hut tub during periods of non-use and retracted during periods of use. Typically, a pool cover box is placed in or on the decking surrounding the swimming pool at a location opposite from the walk-in steps (i.e., usually located at the deep end of the pool). The pool cover box extends across the width of the swimming pool and within the box is mounted a tube or drum to store the pool cover on. Located at one end of the drum is a reel or reels lines connecting to the pool cover, an electric motor and a drive mechanism. The motor is used to turn the drive mechanism which drives the reel or reels to deploy and retract the pool cover.

Drive mechanisms or engagement devices for driving an extension and a retraction of the pool cover are known. For example, U.S. Pat. No. 9,353,539 discloses a cover assembly for covering a swimming pool. The cover assembly includes a drive shaft having a drive pin and an engagement device configured for moving axially on the drive shaft when the drive pin engages the engagement device. The engagement device can be a spiral jaw clutch system having a double drive member with a diagonal cam slot, an end member associated with a cover drum and an end member associated with a reel.

One problem with such engagement devices is that the double drive member must be mounted to a drive shaft in a specific orientation depending upon whether a motor-left or a motor-right orientation is used.

Another problem with such engagement devices is the amount of space required to operate the cover assembly. The motors, drive mechanism and the reels used to extend and retract the pool cover are located at one end of the drum used to store the pool cover on. Having the motors, drive mechanism and reels in this configuration requires a space much greater than the width of the pool cover. In other words, less space in or on the decking surrounding the pool is available for use.

SUMMARY OF THE INVENTION

The invention in one form is directed to a cover assembly for covering a pool or a hot tub. The cover assembly includes a tube, a plurality of mounting brackets, a flexible cover, a pair of lines, a plurality of line guides and a drive arrangement. The tube has a first end, a second end and an internal opening having an inside diameter. The flexible cover has a leading edge and a trailing edge that is connected to the tube. The flexible cover is movable between an extended position and a retracted position over the pool or the hot tub. Each of the lines have a first end and a second end where the first end is connected to the leading edge of the flexible cover. The plurality of line guides are configured to guide the pair of lines. The drive arrangement moves the cover between the extended position and the retracted position. The drive arrangement includes at least one reel configured for winding of the pair of lines. Each reel is connected to a second end of a corresponding one of the lines. A first motor is positioned at least partially within the internal opening of the tube. The first motor has a fixed end and a rotatable end. The fixed end is attached to a corresponding one of the mounting brackets and the rotatable end engages the inside diameter of the tube. The first motor is configured to retract the cover. A second motor is positioned at least partially within the internal opening of the tube. The second motor has a second fixed end and a second rotatable end. The second fixed end is attached to a corresponding one of the mounting brackets and the second rotatable end engages the at least one reel. The second motor is configured to retract the pair of lines.

The invention in another form is directed to a drive arrangement for moving a pool cover between an extended position and a retracted position. The drive arrangement includes a tube, at least one reel, a first motor and a second motor. The tube has a first end, a second end and an internal opening with an inside diameter. Each reel is connected to a second end of a corresponding one of the lines. Each reel is also configured for winding of a pair of lines. The first motor is positioned at least partially within the internal opening of the tube. The first motor engages the inside diameter of the tube and is configured to retract the cover. A second motor is positioned at least partially within the internal opening of the tube. The second motor engages the at least one reel and is configured to retract the pair of lines.

An advantage of the present invention is the elimination of components used in cover assemblies such as shifting dogs and clutches.

BRIEF DESCRIPTION OF THE DRAWINGS

The above-mentioned and other features and advantages of this invention, and the manner of attaining them, will become more apparent and the invention will be better understood by reference to the following description of the embodiment of the invention taken in conjunction with the accompanying drawings, wherein:

FIG. 1 is a perspective view of a swimming pool which can include a pool cover assembly of the present invention;

FIG. 2 is another perspective view of a swimming pool with a pool covering assembly of the present invention;

FIG. 3 is a top view of the drive arrangement forming part of the pool covering assembly of the present invention; and

FIG. 4 illustrates another embodiment of a drive arrangement forming part of the pool covering assembly of the present invention.

Corresponding reference characters indicate corresponding parts throughout the several views. The exemplifications set out herein illustrate embodiments of the invention and such exemplifications are not to be construed as limiting the scope of the invention in any manner.

DETAILED DESCRIPTION OF THE INVENTION

Referring now to the drawings, and more particularly to FIG. 1, there is shown an embodiment of a swimming pool 100 which can include a cover assembly 5 of the present invention. The swimming pool 100 generally includes a deck 112, a coping 114, a cover 22, a leading edge bar 118 and a pool cover box 120.

Deck 112 is generally horizontal and is preferably constructed from concrete. Coping 114 connects to deck 112 in a substantially coplanar fashion along the edge of deck 112 facing the interior of swimming pool 100.

Coping 114 is connected to deck 112 and provides a track allowing leading edge bar 118 to slide therein. The general shape of the exposed portion of coping 114 is generally curved such that there are no exposed sharp corners.

Cover 22 is attached to leading edge bar 118 which pulls cover 22 from pool cover box 120, through an opening existing between pool cover box 120 and a top edge of swimming pool 100, and across the length of swimming pool 100. To prepare swimming pool 100 for use, cover 22 retracts into pool cover box 120 pulling leading edge bar 118 to the previously described opening.

Leading edge bar 118 is connected to cover 22 and provides support along the leading edge of cover 22. Each end of the leading edge bar 118 is connected to at least one cable, rope, or cord (rope being the term used herein but representing any such cable, rope, cord, or the like) and is slidably connected to a track in coping 114. Leading edge bar 118 is shaped in a manner to be unobtrusive and aesthetically pleasing when located at either end of swimming pool 100. Although coping 114 is shown as including an integral track for leading edge bar 118 and cover 22, it is also possible that a pair of top mounted tracks may be mounted to deck 112 along either side of swimming pool 100.

Referring now to FIGS. 1 and 2, conjunctively, the cover assembly 5 generally includes the cover box 120, coping 114, and flexible cover 22. The cover assembly 5 also includes within the cover box 120 a tube 10, a plurality of mounting brackets 20, a pair of lines 28, a plurality of line guides 34, and a drive arrangement 36. The tube 10 has a first end 12, a second end 14 and an internal opening 16 with an inside diameter 18. The tube 10 may be made from any suitable material, e.g., stainless steel or aluminum. The plurality of mounting brackets 20 are attached to the base. The plurality of mounting brackets 20 may be made of any suitable material, e.g., stainless steel or aluminum, and are generally configured to provide support to the cover assembly 5. The flexible cover 22 has a leading edge 24 and a trailing edge 26 which is connected to the tube 10. The flexible cover 22 may be made of any suitable material, such as a UV-stabilized polyethylene, polypropylene, or vinyl. The flexible cover 22 may have a solid color or can be transparent/opaque. The pair of lines 28 each have a first end 30 connected to the leading edge 24 of the flexible cover 22. The pair of lines 22 may be made of any suitable material that provides abrasion, chemical and/or UV resistance, e.g., stainless-steel cables, nylon rope, polypropylene, polyester or other synthetic fibers. The plurality of line guides 34 are arranged to guide the pair of lines 28 around the cover assembly 5. The plurality of line guides 34 may be of any type of device used for guiding a line, e.g., a block having grooves or slots that allow the line to slide through the block, or a pulley that rotates and/or pivots as line moves through the pulley. The plurality of line guides 34 may be made of any suitable material used for guiding a line, e.g. stainless steel, aluminum or plastic.

The drive arrangement 36 is configured for moving the flexible cover 22 between an extended position and a retracted position. The drive arrangement 36 includes at least one reel 38 configured for winding of the pair of lines 28. Each reel 38 is connected to a second end 32 of a corresponding one of the lines 28. The drive arrangement 36 further includes a first motor 40 and a second motor 46. The first motor 40 is positioned at least partially within the internal opening 16 of the tube 10. The first motor 40 has a fixed end 42 (FIG. 2) and a rotatable end 44 (FIG. 2), with the fixed end 42 being attached to a corresponding one of the mounting brackets 20 and the rotatable end 44 engaging the inside diameter 18 of the tube 10. In the illustrated embodiment, the first motor 40 is configured to retract the flexible cover 22. The first motor 40 may be of any size, e.g. ¾ HP, and may be water resistant or water proof. The second motor 46 is positioned at least partially within the internal opening 16 of the tube 10. The second motor 46 has a second fixed end 48 (FIG. 2) and a second rotatable end 50 (FIG. 2), the second fixed end 48 being attached to a corresponding one of the mounting brackets 20 and the second rotatable end 50 engaging the at least one reel 38. The second motor 46 is configured to wind the reels 38 and thereby retract the pair of lines 28. The second motor 46 may be of any size, e.g., ¾ HP, and may be water resistant or water proof. The first motor 40 and the second motor 46 may be connected in parallel or in a series with a power source 52 and/or a motor controller 54. The first motor 40 and the second motor 46 may be similarly sized, e.g., both motors are ¾ HP, or one motor may be sized larger than the other, e.g., one motor is ½ HP and the other motor is ¾ HP. It is to be understood that the motor size ratings are for illustration purposes only and that the motor sizes may be selected to meet the design requirements needed to extend and retract the flexible cover 22.

Referring now to FIG. 2, the drive arrangement 36 may be further provided with a power source 52 and a motor controller 54. The first motor 40 and the second motor 46 may be connected in parallel or in series with the power source 52 and/or the motor controller 54. The power source 52 may be AC or DC and the motor controller 54 may allow for distinct position control, e.g. fully retracted or fully extended, or the motor controller may allow for variable position control, e.g. at any point between and including fully retracted and fully extended. The motor controller 54 may also allow for varying the speed at which the flexible cover 22 moves. The motor controller 54 may also be provided with a key, key pad or other feature suited for the prevention of use.

Operation of the cover assembly 5 may be accomplished with the motor controller 54 or any other device(s) suited for driving the first motor 40 and the second motor 46. A key or keypad entry into the motor controller 54 allows a user to move the flexible cover 22. For example, selecting ‘uncover’ or any other term or figure or symbol defined to move the flexible cover 22 off of the pool or hot tub on the motor controller 54, causes the first motor 40 to rotate the tube 10 such that the flexible cover 22 is wound onto the tube 10. The second motor 46 may be off when the first motor 40 is on. This allows the second motor 46 and the at least one reel 28 having the pair of lines 28 wound upon it to freewheel, i.e., move relative to the first motor 40 motion. Freewheeling of the second motor 46 and the at least one reel 28 having the pair of lines 28 wound upon it allow the lines 28 to unwind as the cover leading edge 24 of the flexible cover 22 moves towards the tube 10. The second motor 46 may also provide a resistance when the first motor 40 is winding the flexible cover 22 onto the tube 10. This resistance advantageously provides a force at the flexible cover leading edge 24, thereby smoothing out wrinkles in the cover that may otherwise be wound onto the tube 10. Preventing wrinkles from being wound onto the tube 10 extends the useful life of the flexible cover 22 as wrinkles in a cover with a load applied may result in cracking of the cover or delamination of materials used in construction of the cover. Providing the resistance during winding of the flexible cover 22 onto the tube 10 may be accomplished by providing the second motor 46 with a voltage or current lower than a voltage supplied to the first motor 40 if the first motor 40 and the second motor 46 are equivalent in size, e.g., both motors are ¾ HP. In other words, the force applied the flexible cover leading edge 24 by the second motor 46 is less than the force applied to the flexible cover 22 by the first motor.

Selecting ‘cover’ or any other term or figure or symbol defined to move the flexible cover 22 onto the pool or hot tub on the motor controller 54, causes the second motor 46 to rotate the at least one reel 38 such that the flexible cover 22 is wound off of the tube 10 as the at least one reel 38 winds up the pair of lines 28. The first motor 40 may be off when the second motor 46 is on. This allows the first motor 40 and the tube 10 having the flexible cover 22 wound upon it to freewheel. Freewheeling of the first motor 40 and the tube 10 having the flexible cover 22 wound upon it allows the flexible cover 22 to unwind as the at least one reel 38 winds up the pair of lines 28. The first motor 40 may also provide a resistance during the time when the second motor 40 is winding the pair of lines 28 onto the at least one reel 38. This resistance advantageously provides a force at the flexible cover leading edge 24 thereby smoothing out kinks in the pair of lines 28 that may otherwise be wound onto the at least one reel 38. Preventing kinks from being wound onto the at least one reel 38 extends the useful life of the pair of lines 28 as kinks in a line wound onto a reel may cause premature wear of the line. The resistance may also prevent a condition where the cover assembly 5 is bound by the kink in the line. Providing the resistance during winding of the pair of lines 28 onto the at least one reel 38 may be accomplished by providing the first motor 40 with a voltage lower than a voltage supplied to the second motor 46 if the first motor 40 and the second motor 46 are equivalent in size, e.g. both motors are ¾ HP. In other words, the force applied the flexible cover leading edge 24 by the second motor 46 is more than the force applied to the flexible cover 22 by the first motor 40.

FIG. 4 illustrates another embodiment of a cover assembly 5 which is similar to the embodiment shown in FIG. 2, with the exception that the second motor 46 is located within the radial interior of the reels 38, rather than within the tube 10.

While this invention has been described with respect to at least one embodiment, the present invention can be further modified within the spirit and scope of this disclosure. This application is therefore intended to cover any variations, uses, or adaptations of the invention using its general principles. Further, this application is intended to cover such departures from the present disclosure as come within known or customary practice in the art to which this invention pertains and which fall within the limits of the appended claims. 

What is claimed is:
 1. A cover assembly for covering a pool or a hot tub, the cover assembly comprising: a tube having a first end, a second end, and an internal opening with an inside diameter; a plurality of mounting brackets; a flexible cover having a leading edge and a trailing edge, the trailing edge being connected to the tube, the flexible cover movable between an extended position and a retracted position; a pair of lines, each of the lines having a first end and a second end, the first end being connected to the leading edge of the flexible cover; a plurality of line guides configured to guide the pair of lines; and a drive arrangement for moving the cover between the extended position and the retracted position, the drive arrangement including: at least one reel configured for winding of the pair of lines, each said reel being connected with a second end of a corresponding one of the lines; a first motor positioned at least partially within the internal opening of the tube, the first motor having a fixed end and a rotatable end, the fixed end being attached to a corresponding one of the mounting brackets and the rotatable end engaging the inside diameter of the tube, the first motor being configured to retract the cover; and a second motor positioned at least partially within the internal opening of the tube, the second motor having a second fixed end and a second rotatable end, the second fixed end being attached to a corresponding one of the mounting brackets and the second rotatable end engaging the at least one reel, the second motor being configured to retract the pair of lines.
 2. The cover assembly of claim 1, wherein the first motor and the second motor are connected to a power source.
 3. The cover assembly of claim 1, wherein the first motor and the second motor are connected in a series.
 4. The cover assembly of claim 2, wherein the power source is connected to a motor controller.
 5. The cover assembly of claim 4, wherein the motor controller provides a first voltage to the first motor and a second voltage to the second motor, the first voltage being higher than the second voltage when the flexible cover is being retracted, the second voltage being higher than the first voltage when the pair of lines are being retracted.
 6. The cover assembly of claim 4, wherein the motor controller provides a first voltage to the first motor and a second voltage to the second motor, the first voltage being lower than the second voltage when the flexible cover is being retracted, the second voltage being lower than the first voltage when the pair of lines are being retracted.
 7. A drive arrangement for moving a pool cover between an extended position and a retracted position, the drive arrangement comprising: a tube having a first end, a second end, and an internal opening with an inside diameter; at least one reel configured for winding of a pair of lines; a first motor positioned at least partially within the internal opening of the tube, the first motor engaging the inside diameter of the tube, the first motor being configured to retract the cover; and a second motor positioned at least partially within the internal opening of the tube, the second motor engaging the at least one reel, the second motor being configured to retract the pair of lines.
 8. The drive arrangement of claim 7, wherein the first motor and the second motor are connected in a series.
 9. The drive arrangement of claim 7, wherein the first motor and the second motor are connected to a motor controller.
 10. The cover assembly of claim 9, wherein the motor controller provides a first voltage to the first motor and a second voltage to the second motor, the first voltage being higher than the second voltage when the flexible cover is being retracted, the second voltage being higher than the first voltage when the pair of lines are being retracted.
 11. The cover assembly of claim 9, wherein the motor controller provides a first voltage to the first motor and a second voltage to the second motor, the first voltage being lower than the second voltage when the flexible cover is being retracted, the second voltage being lower than the first voltage when the pair of lines are being retracted.
 12. A cover assembly for covering a pool or a hot tub, the cover assembly comprising: a tube having a first end, a second end, and an internal opening with an inside diameter; a plurality of mounting brackets; a flexible cover having a leading edge and a trailing edge, the trailing edge being connected to the tube, the flexible cover movable between an extended position and a retracted position; a pair of lines, each of the lines having a first end and a second end, the first end being connected to the leading edge of the flexible cover; a plurality of line guides configured to guide the pair of lines; and a drive arrangement for moving the cover between the extended position and the retracted position, the drive arrangement including: at least one reel configured for winding of the pair of lines, each said reel being connected with a second end of a corresponding one of the lines; a first motor positioned at least partially within the internal opening of the tube, the first motor having a fixed end and a rotatable end, the fixed end being attached to a corresponding one of the mounting brackets and the rotatable end engaging the inside diameter of the tube, the first motor being configured to retract the cover; and a second motor positioned within at least least one of the internal opening of the tube and the at least one reel, the second motor being configured to retract the pair of lines. 